Automated Bop Control and Test System

ABSTRACT

A method and apparatus for testing a blowout preventer which includes a plurality of safety devices and an assembly of fluid control valves that are remotely actuatable to an open and closed position for controlling flow of drilling fluids into a well includes a hydraulic power unit control station for remotely and selectively actuating one or more safety devices and fluid control valves to a test orientation. A hydrostatic test system supplies fluid under first and second test pressure and documents any pressure loss due to fluid leaks within a closed system.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/137,232 filed Sep. 20, 2018 which is a continuation of U.S.application Ser. No. 15/086,419 filed Mar. 31, 2016 which claimspriority to provisional application Ser. No. 62/143,995, filed Apr. 7,2015, the entire contents of which are incorporated herein by referencethereto.

BACKGROUND OF THE INVENTION Field of the Invention

This invention relates to an automatic testing system for testing thefunctionality and integrity of various components of a blowout preventer(BOP). A blowout preventer typically includes a number of safety devicesfor preventing high pressure within a formation from creating a blowoutsituation. Also, a plurality of control valves to direct the flow ofpressurized drilling fluid in a safe and controlled manner areassociated with the BOP. It is necessary to periodically pressure testthese components.

Description of Related Art

Oil and Gas Exploration risk management includes the ability to controlsubsurface pressures which may be encountered during drilling operation.The primary mechanism utilized by operators to control downhole pressureis the hydrostatic pressure as a result of the drilling fluid containedwithin the wellbore. The drilling fluid is engineered and formulated toa density that provides a hydrostatic pressure inside of the wellborethat is greater than the formation pressure being drilled. In themajority of drilling operations, the hydrostatic control of wellborepressure is adequate. However, from time-to-time the operator mayencounter a higher than expected formation pressure where there is notadequate hydrostatic pressure to control the wellbore pressure. Duringthese times the operator relies on a series of mechanical controls tostabilize the wellbore and prevent a “Blow Out”. A blow out is theuncontrolled release of fluid or gas from the wellbore. This event isextremely dangerous and therefore must be avoided if at all possible.The primary mechanical control device utilized by operators to controlwellbore pressure is the Blowout Preventer (BOP) assembly. The BOPassembly typically consists of multiple sealing and shearing devicesthat are hydraulically actuated to provide various means of sealingaround the drill string or shearing it off entirely, thereby completelysealing the wellbore. Additionally, there is a series of valves attacheddirectly to or remotely located in close proximity to the BOP assemblythat make up the pressure control manifold assembly and are inclusive tothe BOP assembly. These valves are opened or closed as required todirect pressurized drilling fluid in a safe and controlled manner.Opening or closing these valves to direct the flow of pressurizeddrilling fluid is commonly referred to within the industry as “aligningthe valves”. Valve alignment is principally a manual operation. It isessential that the BOP assembly operates as designed during criticaloperations. Therefore, it is a regulatory requirement to test thefunctionality and the integrity of the BOP assembly before startingdrilling operations and at specific events during the drillingoperations. Typically, the interval between these tests is approximately14 days. The BOP Assembly test is a series of pressure tests at aminimum of two pressure levels, low pressure and high pressure. Eachtest of the series of tests is carried out according to a “Test Plan”.The test plan specifies, among other test requirements, the precisealignment of the valves applicable to the test. A typical test plan caninclude as many as 30 or more valves which may be required to be aligneddifferently for each pressure test. FIG. 1 depicts a typical BOPassembly with the internal multiple sealing and shearing devices such asAnnular 34, Pipe Rams 35, and Blind Rams 36, as well as the externalvalves numbered 1 through 32. The alignment of the valves is a timeconsuming and problematic manual operation. Proper valve alignment isfully reliant on the diligence of the rig personnel and there is novisual indication that the valves are properly aligned. Conversely themultiple sealing and shearing devices within the BOP are fully automatedand remotely operated via an automated hydraulic control system. Duringa typical BOP assembly pressure test, rig personnel would quickly andaccurately align the multiple sealing and shearing devices within theBOP assembly, utilizing the automated controls, as specified by the testplan, but would be required to manually align the BOP Assembly valvesoutside of the BOP. The pressure test would commence once the multiplesealing and shearing devices and valves of the BOP assembly are deemedand confirmed to be aligned properly as specified by the test plan.During the pressure test, intensifying fluid from a high-pressureintensifying pump unit is introduced into the BOP assembly in a volumesufficient to cause the internal pressure within the BOP assembly torise to the specified level indicated on the test plan. Thehigh-pressure intensifying pump is normally a truck or trailer mountedunit which is transported to the rig location when pressure testing isrequired. These are referred to within the industry as “hydrostatic testunits”. The portable hydrostatic test units will remain on locationuntil the test plan is completed, usually about 12 hours. Portablehydrostatic test units are typically a manually operated device wherethe technician engages or disengages the pump to achieve the testpressure specified by the test plan. Coordination between the drillingrig personnel who are controlling the BOP assembly test and the trucktechnician is typically handled via a two-way radio. When the rigpersonnel are reasonably sure the BOP assembly valves are alignedcorrectly and they deem it safe to conduct a test, they will radio thetruck to commence the test. Subsequent to a successful pressure test theBOP assembly will be aligned for the next test. This procedure would berepeated multiple times until the entire test plan was completed. Aschematic of a rig setup typical of current technology as describedabove is depicted in FIG. 2. BOP assembly internal sealing and shearingdevices 34, 35, 36, of BOP 40 and hydraulic power unit 50 are in controlfluid communication via control fluid conduit 45. Control fluid conduit45 is made up of multiple discrete fluid control circuits. BOP assemblyexternal valves 41 are in intensifying fluid communication with BOPassembly 40. Hydraulic power unit 50 includes a local control station60. Hydraulic power unit 50 is in signal communication with remotecontrol station 70 via signal cable 80. BOP assembly external valves 41are manually operated as required. Additionally, during the test periodportable hydrostatic test system 90 is temporally placed in intensifyingfluid communication with BOP assembly internal sealing and shearingdevices 34-36 via intensifying fluid conduit 100. During a typicalpressure test of the BOP assembly, BOP assembly internal sealing andshearing devices 34, 35, and 36 are aligned according to the test planby providing the proper control signals from remote control station 70via signal cable 80. BOP assembly external valves 1-32 are manuallyaligned as required by the test plan. The rig personnel confirm that thevalves are properly aligned and that it is safe to proceed with thepressure test. The rig personal will signal the technician of portablehydrostatic test system 90 via a two-way radio to commence the pressuretest. The technician of portable hydrostatic test system 90 willmanually initiate the high-pressure intensifying pump of portablehydrostatic test system 90. High pressure intensifying fluid fromportable hydrostatic test system 90 will intensify the internal pressureof BOP assembly internal sealing and shearing devices 42 and BOPassembly external valves 41 according to the specific alignment scheduleof the test plan via intensifying fluid conduit 100. Subsequent to asuccessful pressure test, intensifying fluid is relieved from BOPassembly internal sealing and shearing devices 35, 36 and BOP assemblyexternal valves 41 via portable hydrostatic test system 90 andintensifying fluid conduit 100. At this point BOP assembly internalsealing and shearing devices 34, 35, 36 and BOP assembly external valves1-32 will be aligned according to the test plan and the next subsequenttest can be initiated. This process is repeated for each test of thetest plan. At the completion of the test plan portable hydrostatic testsystem 90 and intensifying fluid conduit 100 will be disconnected fromthe BOP assembly in preparation for transportation to the rig sight. Inapproximately 14 days the entire process will be repeated.

The entire pressure cycle of these tests is performed without the use ofautomation. Automating this process would help to ensure continuity andsafety of the pressure procedure between the hydrostatic unit and theBOP assembly. The manual and separate nature of the test procedure isproblematic and dangerous. Additionally, the manual process of aligningthe valves is very time consuming. It is not uncommon for this part ofthe test to consume more time than the actual pressure test. It would bemuch more desirable to have an improved system that fully automates thealignment of the valves. Hydraulically operated valves are commerciallyavailable, for example the Valves Works USA FC series valve, and aresuitable for use as a component of a fully automated BOP Assemblyoperating and testing system. These valves respond to intensifiedhydraulic fluid to open or close as directed by control valves and ahydraulic power source. Alternatively, other types of valves could beused which are electrically or air operated. Thus, there remains a needfor a fully automated system to provided BOP Assembly operating andtesting capabilities integral to one system capable of being operatedfrom a single remote-control panel, a single local control panel, or aspart of an automated drilling control system.

BRIEF SUMMARY OF THE INVENTION

The present invention is directed to a system and method for pressuretesting a BOP assembly that includes a plurality of hydraulicallyactuated safety devices and a plurality of valves for regulatingdrilling fluid pressure within the well.

The invention includes the provision of remotely actuatable valves thatcan be positioned for testing purposes automatically and remotely by thesame hydraulic power source used to actuate the safety devices in theevent of an emergency. Alternately the valves may be remotely actuatedby an electrical power source selectively connected to electricalactuators such as solenoids provided on the valves.

The following detailed description and drawings of the preferredembodiment of the Automated BOP Control and Test System is intended asan exemplification of the principals of the invention and not intendedto limit the invention to any specific embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a conventional blowout preventer showingvarious safety control devices and pressure controlling valves.

FIG. 2 is a schematic showing of a conventional testing arrangement fora blowout preventer.

FIG. 3 is a schematic showing of an automated control and testing systemfor a blowout preventer according to an embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As shown in FIG. 1, a typical blowout preventer assembly 40 includes aplurality of valves 1-32 for controlling the pressurized drilling fluidin a safe and controlled manner.

BOP assembly 40 also includes a number of sealing and shearing devices34, 35 and 36 that are hydraulically actuated to provide various meansof sealing around the drill string or shearing it off completely.

In this example, the BOP includes an annular sealing device 34, piperams 35 and blind rams 36.

A typically testing arrangement is shown in FIG. 2. The blowoutpreventer assembly 40 is connected to a hydraulic power unit 50 utilizedto actuate the safety devices 34, 35, and 36 in the event of anemergency. Hydraulic power unit 50 may be controlled by a local controlstation 60 or a remote-control station 70 via a control cable 80 or awireless control.

The safety devices and external valves are connected to a portablehydraulic test system 90 which generates testing fluid under variouspressures for testing the integrity of the various valves and safetydevices as described above.

As an example, the chart below illustrates a typically sequence of testsinvolving the various valves and safety devices. The valves are alignedand set by hand.

Test Low Test High Test Number Test Against Pressure & Times Pressure &Times Test 1 V1, V2, V8 Pipe Rams, Low: 250 psi, 5 minutes High: 5000psi, 10 minutes V20, V22, V24, V25 Test 2 V7, V (, Pipe Rams, Low: 250psi, 5 minutes High: 5000 psi, 10 minutes V19, V21, V23, V25 Test 3Topdrive Hydraulic Low: 250 psi, 5 minutes High: 5000 psi, 10 minutesValve, Pipe Rams, V10, V13 Test 4 Lower Topdrive Low: 250 psi, 5 minutesHigh: 5000 psi, 10 minutes Manual Valve, Pipe Rams, V11, V12 Test 5Lower Topdrive Low: 250 psi, 5 minutes High: 3500 psi, 10 minutes ManualValve, ANNULAR PREVENTER, V11, V12 Test 6 V14, Blind Rams, V19, Low: 250psi, 5 minutes High: 5000 psi, 10 minutes V21, V23 Test 7 Casing, V14Blind Low: 250 psi, 5 minutes High: 1500 psi, 30 minutes Rams, V19, V21,V23, V15, V18 Test 8 Cup Type Tester, V14, Low: 250 psi, 5 minutes High:5000 psi, 10 minutes Pipe Rams, V19, V21, V23, V15, V18 Test 9 Cup TypeTester, V14, Low: 250 psi, 5 minutes High: 5000 psi, 10 minutes PipeRams, V19, V21, V23, V16, V17

Referring to FIG. 3 of an embodiment of the invention will be described.

A schematic of a rig setup utilizing the new and unique features of thecurrent invention is depicted in FIG. 3. BOP assembly internal sealingand shearing devices 34-36, BOP 40 assembly external automated valves1-32 shown schematically at 41, and hydraulic power unit 50 are incontrol fluid communication via control fluid conduit 45. Control fluidconduit 45 is made up of multiple discrete fluid control circuits.Hydraulic power unit 50 may include local control station 60. Hydraulicpower unit 50 and hydrostatic test system 90 are also in signalcommunication with remote control station 70 via signal cable 80.Hydrostatic test system 90 is in intensifying fluid communication withBOP assembly internal sealing and shearing devices 34-36 viaintensifying fluid conduit 100. A suitable hydrostatic test system isdisclosed in U.S. patent application Ser. No. 14/932,727 filed Nov. 4,2015, the entire contents of which is incorporated herein by referencethereto. BOP assembly external automated valves 1-32 are in intensifyingfluid communication with hydrostatic test system 90 via conduit 101.During a test utilizing the new and unique features of the currentinvention, BOP assembly internal sealing and shearing devices 34-36 andBOP assembly external automated valves 1-32 are aligned according to thetest plan by providing the proper control signals from remote controlstation 70 via signal cable 80. For Example: test 1 of the test plandepicted in the chart requires closing the pipe rams of BOP Assembly aswell as BOP assembly external automated valves numbers 1, 2, 8, 20, 22,24, and 25. A suitable computer program within remote control station 70would enable the specific solenoid valve of hydraulic power unit 50, viasignal cable 80, directing hydraulic control fluid, via control fluidconduit 45 to close the Pipe Rams of BOP assembly 40. Additionally thesuitable computer program within remote control station 70 would enablethe specific solenoid valves of hydraulic power unit 50, via signalcable 80, directing intensified hydraulic control fluid, via controlfluid conduits 45 and 46 to close BOP assembly external automated valvesnumbers 1, 2, 8, 20, 22, 24, and 25. Subsequent to remote controlstation 70 confirming proper alignment of BOP assembly internal sealingand shearing devices 34-36 and BOP assembly external automated valves1-32 via signal cable 80, remote control station 70 will initiate thehydrostatic pressure test of BOP assembly internal sealing and shearingdevices 34-36, and selected BOP assembly external automated valves 1-32via signal cable 80. High pressure intensifying fluid from hydrostatictest system 90 will intensify the internal pressure of BOP assemblyinternal sealing and shearing devices 34-36 and BOP assembly externalvalves 1-32 according to the specific alignment schedule of the testplan via intensifying conduits 100 and 101.

Subsequent to a successful pressure test, intensifying fluid is relievedfrom BOP assembly internal sealing and shearing devices 34-36 and BOPassembly external valves 1-32 via hydrostatic test system 90 andintensifying fluid conduits 100 and 101. BOP assembly internal sealingand shearing devices 34-36 and BOP assembly external valves 1-32 will bealigned for the next test according to the test plan by providing theproper control signals from remote control station 70 via signal cable80 to hydraulic power unit 50 and hydrostatic test system 90 so the nextsubsequent test can be initiated. This process is repeated for each testof the test plan.

Utilizing the new and unique features of the current invention providesfor fully automatic, integrated, BOP assembly operation and testingthereby significantly increasing safety, while dramatically reducingcost. The principles, preferred embodiment, and mode of operation of thepresent invention have been described in the foregoing specification.This invention is not to be construed as limited to the particular formsdisclosed, since these are regarded as illustrative rather thanrestrictive. Moreover, variations and changes may be made by thoseskilled in the art without departing from the spirit of the invention.For example, an electrical control system could be used for electricallycontrolling valve 1-32 to an open or closed position with the use ofsolenoid-controlled valves.

Although the present invention and its advantages have been described indetail, it should be understood that various changes, substitutions andalterations may be made herein without departing from the spirit andscope of the invention as defined by the appended claims.

What is claimed is:
 1. A method of conducting a pressure test for ablowout preventer which includes a plurality of safety devices operatedby hydraulic pressure and for an assembly of fluid control valves andconduits for directing pressurized drilling fluid into or out of awellbore, the fluid control valves being remotely actuated to an open orclosed position comprising; a) determining a test plan for testingisolated portions of the blowout preventer and fluid control valves andconduits, b) causing pressurized fluid from a hydraulic power unit toalign one or more of the safety devices within the blowout preventer, c)remotely actuating the fluid control valves to an open or closedposition according to the test plan, and d) applying a first fluid testpressure to the blowout preventer and to the assembly of fluid controlvalves and conduits via a hydraulic test system.
 2. The method of claim1 including the step of applying a second fluid test pressure to theblowout preventer and assembly of fluid control valve and conduits. 3.The method of claim 2 including the step of selecting one or moredifferent safety devices according to the test plan and selecting one ormore different fluid control valves to close and causing pressurizedfluid to operate the one or more safety devices and to close the one ormore different fluid control valves according to the test plan.
 4. Themethod of claim 1 wherein the hydraulic power unit supplies pressurizedfluid to the blowout preventer for operating the safety devices in theevent of an emergency and also provides pressurized fluid for remotelycontrolling the fluid control valves to an open or closed position,during a test procedure.
 5. The method of claim 4 further compressingthe step of providing a hydraulic power unit remote control station forcontrolling the hydraulic power unit.
 6. The method of claim 5 furthercomprising sensing the condition of the fluid control valves and sendingthis information about the condition to the hydraulic unit remotecontrol station.
 7. The method of claim 1 further comprising the step ofproviding a hydraulic power unit local control station.
 8. Apparatus fortesting a blowout preventer having a plurality of safety devices and anassembly of fluid control valves and conduits for directing drillingfluid into a well comprising; a) a hydraulic power unit for operatingone or more of the safety devices in the blowout preventer in the eventof an emergency, b) a hydrostatic test system for pressurizing one ormore safety devices and the assembly of fluid control valves to a firsttest pressure, c) the fluid control valves adapted to be remotelycontrolled to an on and off state, and a hydraulic power control unitcoupled to the hydraulic power unit to remotely and to selectivelycontrol the safety devices in the blowout preventer and the state of thefluid control valves during a test cycle.
 9. Apparatus for testing ablowout preventer as claimed in claim 8 further including acommunications link between the hydraulic power unit and the hydraulicpower unit control station for selectively actuating the safety devicesand closing the valves to an off condition in accordance with a testplan.
 10. Apparatus as claimed in claim 8 wherein the hydrostatic testsystem is also controlled by the hydraulic power unit control station.11. Apparatus as claimed in claim 8 wherein the hydrostatic test systemis adapted to supply fluid under a first test pressure and a second testpressure to the blowout preventer.
 12. The apparatus of claim 8 whereinthe blowout preventer is in fluid communication with the assembly offluid valves and conduits.
 13. The apparatus of claim 8 wherein thefluid control valves are electrically operated from a closed position toan open position.
 14. The apparatus of claim 8 wherein the fluid controlvalves are hydraulically or pneumatically opened from a closed positionto an open position.
 15. The method of claim 1 wherein the fluid controlvalves are actuated electrically.
 16. The method of claim 1 wherein thefluid control valves are actuated hydraulically or pneumatically.